Skid mounted oil well production processing system

ABSTRACT

A modular skid mounted oil production system, comprising multiple skid sections that are connectable via alignment pins coupled to the skid beam structure. The alignment pins having a fork connector that is connected to a knife connector. When the skid sections are connected, the piping, electrical, and pneumatic tubing connectors are connectable to the other corresponding skid piping, electrical, and pneumatic tubing connectors without the need for welding or field construction of connecting components. The modular skid oil production system is capable of expansion or contraction as required by the operation of the system. For example the system includes removing a skid section having a larger separator and replacing it with a skid section having a smaller separator, without the need of welding or field construction of connecting components.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit, and priority benefit, of U.S.Provisional Patent Application Ser. No. 62/483,988, filed Apr. 11, 2017,titled “SKID MOUNTED OIL WELL PRODUCTION PROCESSING SYSTEM,” thedisclosure of which is incorporated by reference herein in its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

FIELD OF THE INVENTION

The present invention relates generally to a skid mounted oil productionprocessing system and method. More particularly, but not by way oflimitation, embodiments of the present invention provide skid mountedoil production systems that include piping, instrument, electrical, andcontrol components and connections, wherein the skid mounted productionsystems are capable of expansion or contraction as the requirements ofthe production well changes without the need to perform welding at thesite.

BRIEF SUMMARY

The following presents a simplified summary of the disclosed subjectmatter in order to provide a basic understanding of some aspects of thesubject matter disclosed herein. This summary is not an exhaustiveoverview of the technology disclosed herein. It is not intended toidentify key or critical elements of the invention or to delineate thescope of the invention. Its sole purpose is to present some concepts ina simplified form as a prelude to the more detailed description that isdiscussed later.

Oil production is the process by which a reservoir fluid is transportedto the surface to be separated into oil, gas and water. If necessary,the obtained oil and gas will be treated and conditioned for sale ortransport from the field to a petroleum refinery. The so called“upstream operations” consist of the exploration, development andproduction of crude oil, water and natural gas.

The production process is carried out in a surface installation. Thisinstallation includes wells, manifolds, pipelines, production lines,separators and other process equipment, as well as measuring equipmentand storage tanks. Over time a well's oil production can decrease byfifty percent (50%), which results in equipment such as separators thatwere originally installed with the inception of the well, beingoversized. However, replacing the equipment with smaller, less expensivein both initial and operating costs would require the production well tobe shutdown and the system purged in order to perform the requisitewelding and running of the various electrical, piping and pneumaticconnections. In some cases the production capabilities of a well mayhave been underestimated and therefore results in the installedequipment being undersized. Embodiments of the present invention resolvethese issues and allow for the contraction or expansion of oilproduction systems using skid mounted components, without the need forwelding onsite.

Additionally, embodiments of the present invention drastically reduceboth shop construction time and installation time. For example,construction time of traditional systems can take in excess of eight (8)weeks to complete, whereas construction of systems in accordance with anembodiment of the present invention can be complete on average offourteen (14) days at a 30-35% reduction of cost and are completelyready for startup with full safety systems. Similarly, installation timeof traditional systems oil production systems, can take four (4) weeksor more to complete. But in stark contrast, an entire system inaccordance with an embodiment of the present invention, including skidsand vessels can be installed and connected in approximately four (4)hours.

In one embodiment, an apparatus, system and method for a portable oilproduction modular system for processing fluids produced by an oil well,having a first skid section having comprising a first piping manifoldfor fluid flow having a first piping manifold connection assembly, afirst separator for separating a water-oil mixture into separate fluidcomponents, and a first set of spaced apart beams on which the firstpiping manifold is mounted. This system also includes a second skidsection that is separable from the first skid section, comprising asecond piping manifold for fluid flow having a second piping manifoldconnection assembly, and a second set of spaced apart beams on which thesecond piping manifold is mounted. This system further includes a forkpin connector having guide plates that is coupled at one end to a beamof one skid section. The other end of the fork pin connector includesangled projections on the guide plates having a pin there between. Insome embodiments, the system can also include a knife connector coupledto a beam of another skid section; wherein the first skid section iscapable of connecting to the second skid section by engagement of thefork and knife connectors, and wherein when the first and second skidsections are connected, the first piping manifold is connectable to thesecond piping manifold via the interconnection of the first pipingmanifold connection assembly and the second piping manifold connectionassembly, without the need for welding. Further, should the oilproduction system for the oil well need a smaller or larger separator, athird skid section comprising a third piping manifold for fluid flowhaving a third piping manifold connection assembly, a second separatorfor separating a water-oil mixture into separate fluid components, and athird set of spaced apart beams on which the third piping manifold ismounted is capable of replacing the first skid section, by disconnectingthe first skid section from the second skid section, and wherein thethird skid section is capable of connecting to the second skid sectionby interconnection of the fork and knife connectors, and wherein whenthe third and second skid sections are connected, the third pipingmanifold is connectable to the second piping manifold via theinterconnection of the third piping manifold connection assembly and thesecond piping manifold connection assembly, without the need forwelding.

In another embodiment, the connector for securing two sections together,includes a angled pin plate having an angled end at one end and theother end being welded to a beam of the skid, wherein as the skids arepushed together the angled end of the pin plate engages the side of theweb of a beam, such as an I-beam.

In another embodiment, the portable oil production modular system alsoincludes the first skid section having a first conduit containing afirst set of conductors capable of carrying electrical signals; and thesecond skid section having a second conduit containing a second set ofconductors capable of carrying electrical signals, wherein the first andsecond sets of conductors are connectable via an interconnection of thefirst and second conduits.

In yet another aspect of an embodiment of the present invention, theportable oil production modular system further includes the third skidsection having a third conduit containing a third set of conductorscapable of carrying electrical signals, wherein when the first skidsection is replaced by the third skid section, the second and third setsof conductors are connectable via an interconnection of the second andthird conduits.

In another aspect of an embodiment of the present invention, theportable oil production modular system further includes a firstelectrical terminator that is connected to the first set of conductors;a second electrical terminator that is connected to the second set ofconductors; and a third electrical terminator that is connected to thethird set of conductors, wherein the second electrical terminator isconnected to the third electrical terminator.

In another aspect of an embodiment of the present invention, theportable oil production modular system further includes a firstelectrical terminator that is connected to the first set of conductors;and a second electrical terminator that is connected to the second setof conductors; wherein the first electrical terminator is connected tothe second electrical terminator.

In yet another aspect of an embodiment of the present invention, theportable oil production modular system further includes the first skidsection having a first pneumatic manifold having a first pneumaticmanifold connection assembly; and the second skid section having asecond pneumatic manifold having a second pneumatic manifold connectionassembly, wherein the first and second pneumatic manifolds areconnectable via an interconnection of the first and second pneumaticmanifold connection assemblies, without the need of welding.

In yet another aspect of an embodiment of the present invention, theportable oil production modular system further includes the third skidsection having a third pneumatic manifold having a third pneumaticmanifold connection assembly, wherein when the first skid section isreplaced by the third skid section, the second and third pneumaticmanifolds are connectable via an interconnection of the second and thirdpneumatic manifold connection assemblies, without the need of welding.

In another aspect of an embodiment of the present invention, the systemincludes an integrated sand separator in at least one of, a pluralityof, or all of the high pressure separators in the system. In thisembodiment, the high pressure separator is connected to the wellhead andincludes an internal sand separator system disposed within the highpressure separator. The sand separator system filters out the majorityof the sand from the well head fluid stream. The sand separator systemincludes a sand weir plate and drain system, wherein when the inlet flowfrom the well head impinges upon an inlet diverter mounted inside thehigh pressure separator vessel, the sand separates from the fluid and iscollected at the base of the sand weir plate. In another aspect of thisembodiment, the high pressure separator includes a self-cleaning sandseparator system, wherein after the separated sand is collected at thebase of the sand weir plate, it is drained from the high pressureseparator. In a further aspect of this embodiment, a sand choke valve isused to remove the sand from the separator, eliminating the need to shutdown the system to vacuum remove the sand.

In yet another aspect of an embodiment of the present invention, a levelmeasuring device, such as an ultrasonic/sonar level device, a radarlevel device, an ultrasonic level device, or a capacitance level devicemeasures the level of collected sand and communicates this level to thecontrol or monitoring system. A further aspect of an embodiment caninclude a control system actuated valve that can be programed andoperated to open in order to drain the sand. Further, the control systemcan send a signal to open the valve based on when the sand level reachesa desired setpoint.

In a further embodiment of the present invention, an oil and gasproduction separator for receiving a production stream comprisingliquids, gas, and solids, the separator comprising: a pressure vesselhaving an interior cavity configured to receive a production streamcomprising oil, gas, water and solids; an inlet nozzle connected to saidvessel and in communication with the interior cavity through which theproduction stream enters the vessel; a first vertical plate attachednear a top surface of an interior wall of the vessel, said firstvertical plate extending vertically downward toward a bottom surface ofthe vessel, wherein the first vertical plate being located near theinlet nozzle; a second vertical plate attached to the bottom surface ofthe interior wall of the vessel, said second vertical plate extendingupward from the bottom surface of the vessel, the second vertical platebeing located adjacent to and a distance behind the first verticalplate; a first outlet nozzle connected to said vessel and incommunication with the interior cavity for removal of solids from theproduction stream, the first outlet nozzle extending from a bottom wallof the vessel between the first vertical plate and the second verticalplate; a second outlet nozzle connected to said vessel and incommunication with the interior cavity for removal of a first fluid fromthe production stream, the second outlet nozzle extending from thebottom wall of the vessel, the second outlet nozzle being located behindthe second vertical plate; a third vertical plate attached to the bottomsurface of the interior wall of the vessel, said third vertical plateextending upward from the bottom surface of the vessel, the thirdvertical plate being located behind the second outlet nozzle, wherein atop of the third vertical plate extends above a top of the secondvertical plate; a third outlet nozzle connected to said vessel and incommunication with the interior cavity, said third outlet nozzleextending from the bottom wall of the vessel for removing a second fluidfrom the production stream, the third outlet nozzle being located behindthe third vertical plate; and a fourth outlet nozzle connected to saidvessel and in communication with the interior cavity for removal of agas, said fourth outlet nozzle extending from an upper wall of thevessel.

In a further embodiment of the present invention, an alignment modulesystem, comprising: a first module, comprising: an alignment beam memberhaving a first end and a second end, a first fork connector having acenterline along its longitudinal axis, said first fork connector inengagement with and coupled to the first end of said alignment beam; anda second fork connector having a centerline along its longitudinal axis,said second fork connector in engagement with and coupled to the secondend of said alignment beam; a second module, comprising: an alignmentbeam member having a first end and a second end, a first pin connectorhaving a centerline along its longitudinal axis, said first forkconnector in engagement with and coupled to the first end of saidalignment beam; and a second pin connector having a centerline along itslongitudinal axis, said second pin connector in engagement with andcoupled to the second end of said alignment beam; wherein, said firstmodule may be secured to the second module by engaging the first pinconnector with the first fork connector and engaging the second pinconnector with the second fork connector.

In another embodiment of the present invention, a stacking system forshipment of multiple pipe racks and other equipment skids on a singletrailer is provided. In this embodiment, stacking posts are bolted to afirst pipe rack steel beam at various points along the length of thefirst pipe rack, and at the other end of the stacking posts, thestacking posts are bolted to a second pipe rack steel beam at variouspoints along the length of the second pipe rack, wherein the second piperack is positioned above the first pipe rack. In this embodiment, asingle trailer can transport both the first and second pipe racks in onetrip. Additionally, third, fourth, and any number of additional piperacks can me mounted on the trailer atop the other pipe racks usingadditional stacking posts. Not only can pipe racks be mounted fortransport and transported on a trailer in this manner, equipment mountedon beams can also be stacked and transported in this manner.

In a further aspect of an embodiment, the system includes a controlsystem, such as a DCS, PLC, SCADA, or wireless control system (e.g.,wireless instrumentation and control devices that communicate over awireless network), or a combination of these types of control systemsthat are operatively in communication with the modular productionsystem's instrumentation, actuators and valves. The control system canbe used to monitor and control the operation of the production systemand operational data that can be used to generate and predict productionsystems operational setpoints, maintenance needs, measurements, andvalues, including service to the equipment, such as the need to drainsand from the integrated sand separator. For example, and as discussedfurther below, there is data collection via a computer communicationnetwork of production system operating parameters and determinedsetpoint data for a production system, including the separator systems,wherein using data analytics, artificial intelligence, machine learningand/or neural network methodologies to: predict the subject, a related,or an unrelated production system's performance and/or operationalsetpoints; generate benchmarking metrics for production systems'operation and maintenance; and/or generate setpoints and anticipatedmeasurement and production system operational values.

The modular production system in accordance with an embodiment of thepresent invention is a production system that can adapt to many andchanging circumstances. It's “plug and Play” design provides the abilityto easily change out the size of equipment, separator, outlet lines,controls, etc., from early life well construction to late well lifeproduction. In a further aspect, when any piece of equipment is pulledout of service, the piping footprint remains the same and any new pieceof equipment can be pushed into play with minimal downtime and noadditional manufacturing or changes to equipment or interconnecting pipeis required.

BRIEF DESCRIPTION OF THE DRAWING

For a more complete understanding of this disclosure, reference is nowmade to the following brief description, taken in connection with theaccompanying drawings and detailed description, wherein like referencenumerals represent like parts.

FIG. 1 depicts a crude oil and/or natural gas production system formultiple wells in accordance with an embodiment of the presentinvention.

FIG. 2 depicts a top view of the system shown in FIG. 1.

FIG. 3 depicts a portion of the system disclosed in FIGS. 1 and 2.

FIG. 4 depicts a portion of the system disclosed in FIGS. 1, 2 and 3.

FIG. 5 depicts a crude oil and/or natural gas production system formultiple wells in accordance with an embodiment of the presentinvention.

FIG. 6A depicts a portion of the system in accordance with an embodimentof the present invention.

FIG. 6B depicts a portion of the system disclosed in FIG. 5 inaccordance with an embodiment of the present invention.

FIG. 7 depicts a portion of the system disclosed in FIGS. 5 and 6B andthe piping and alignment pin connections in accordance with a furtherembodiment of the invention.

FIG. 8 depicts a portion of the system disclosed in FIGS. 5, 6 and 7 andthe piping and alignment pin connections.

FIG. 9 depicts an expanded view of the rigid beam alignment connectionsin accordance with an embodiment of the present invention.

FIG. 10 depicts an expanded view of the rigid beam alignment connectionsand electrical conductor and pneumatic tubing connections in accordancewith an embodiment of the present invention.

FIG. 11 depicts an expanded view of the piping flanged connections,rigid beam alignment connections and electrical conductor and pneumatictubing connections in accordance with an embodiment of the presentinvention.

FIG. 12A depicts an integrated sand separator in accordance with anembodiment of the present invention.

FIG. 12B depicts an integrated sand separator schematic in accordancewith an embodiment of the present invention.

FIG. 13 depicts an integrated sand separator in accordance with anembodiment of the present invention.

FIG. 14 depicts a fork pin alignment connector in accordance with anembodiment of the present invention.

FIG. 14A depicts a side sectional view of a guide plate of the forkdepicted in FIG. 14 in accordance with an embodiment of the presentinvention.

FIG. 15 depicts a knife alignment connector in accordance with anembodiment of the present invention.

FIG. 16 depicts a Cold Weather Packaging Modular Production System inaccordance with an embodiment of the present invention.

FIG. 17 depicts a stacking spacer in accordance with an embodiment ofthe present invention.

FIG. 18 depicts a stacking system in accordance with an embodiment ofthe present invention.

FIG. 19 depicts a section of a stacking system in accordance with anembodiment of the present invention.

FIG. 20 depicts is a neural network (NN) architecture 600 implemented inan embodiment of the present invention.

FIG. 21A depicts a guide projection in accordance with an embodiment ofthe present invention.

FIG. 21B depicts two pipe rack skid sections secured to each other viathe guide projection.

FIG. 21C depicts two pipe rack skid sections secured to each other viathe guide projection.

While certain embodiments will be described in connection with thepreferred illustrative embodiments shown herein, it will be understoodthat it is not intended to limit the invention to those embodiments. Onthe contrary, it is intended to cover all alternatives, modifications,and equivalents, as may be included within the spirit and scope of theinvention as defined by claims. In the drawing figures, which are not toscale, the same reference numerals are used throughout the descriptionand in the drawing figures for components and elements having the samestructure, purpose or function.

DETAILED DESCRIPTION

Turning now to the detailed description of the preferred arrangement orarrangements of various embodiments of the present invention, it shouldbe understood that, although an illustrative implementation of one ormore embodiments are provided below, the inventive features and conceptsmay be manifested in other arrangements and that the scope of theinvention is not limited to the embodiments described or illustrated.The various specific embodiments may be implemented using any number oftechniques known by persons of ordinary skill in the art. The disclosureshould in no way be limited to the illustrative embodiments, drawings,and/or techniques illustrated below, including the exemplary designs andimplementations illustrated and described herein. The scope of theinvention is intended only to be limited by the scope of the claims thatfollow. Furthermore, the disclosure may be modified within the scope ofthe appended claims along with their full scope of equivalents.

While the making and using of various embodiments of the presentdisclosure are discussed in detail below, it should be appreciated thatthe present disclosure provides many applicable inventive concepts thatcan be embodied in a wide variety of specific contexts. The specificembodiments discussed herein are merely illustrative of specific ways tomake and use the disclosure and do not limit the scope of thedisclosure.

The present disclosure will now be described more fully hereinafter withreference to the accompanying figures and drawings, which form a parthereof, and which show, by way of illustration, specific exampleembodiments. Subject matter may, however, be embodied in a variety ofdifferent forms and, therefore, covered or claimed subject matter isintended to be construed as not being limited to any example embodimentsset forth herein; example embodiments are provided merely to beillustrative. Likewise, a reasonably broad scope for claimed or coveredsubject matter is intended. Among other things, for example, subjectmatter may be embodied as methods, devices, components, or systems. Thefollowing detailed description is, therefore, not intended to be takenin a limiting sense.

Throughout the specification and claims, terms may have nuanced meaningssuggested or implied in context beyond an explicitly stated meaning.Likewise, the phrase “in one embodiment” as used herein does notnecessarily refer to the same embodiment and the phrase “in anotherembodiment” as used herein does not necessarily refer to a differentembodiment. It is intended, for example, that claimed subject matterinclude combinations of example embodiments in whole or in part.

In general, terminology may be understood at least in part from usage incontext. For example, terms, such as “and”, “or”, or “and/or,” as usedherein may include a variety of meanings that may depend at least inpart upon the context in which such terms are used. Typically, “or” ifused to associate a list, such as A, B or C, is intended to mean A, B,and C, here used in the inclusive sense, as well as A, B or C, here usedin the exclusive sense. In addition, the term “one or more” as usedherein, depending at least in part upon context, may be used to describeany feature, structure, or characteristic in a singular sense or may beused to describe combinations of features, structures or characteristicsin a plural sense. Similarly, terms, such as “a,” “an,” or “the,” again,may be understood to convey a singular usage or to convey a pluralusage, depending at least in part upon context. In addition, the term“based on” may be understood as not necessarily intended to convey anexclusive set of factors and may, instead, allow for existence ofadditional factors not necessarily expressly described, again, dependingat least in part on context.

FIG. 1 depicts a crude oil and/or natural gas production systemcomprising a cluster of four (4) wells (not shown). As shown in FIG. 1,a production system according to an embodiment of the invention in whicha multiphase fluid mixture comprising crude oil, water, natural gasand/or other fluids is produced by a cluster of four (4) wells (notshown) and transported via multiphase fluid transport pipelines toindividual well high pressure bulk separators 10, 20, 30 and 40, and lowpressure separator 50. As shown in FIG. 1, the equipment, including thepiping, instrumentation, and pipe rack is mounted on several skidsections. The system also includes a fuel gas scrubber 60, tank battery70 having ten (10) storage tanks 70 a-70 k, which store water, oil andother fluids and materials that are produced by the wells. FIG. 1 alsoshows the system including vapor recovery tower 80, flare knock-out drum90 and flare stack 100.

FIG. 2 depicts a top view of the production system shown in FIG. 1. Asshown in more detail in FIG. 2, the system includes a pipe rack 110 thatis made of multiple sections 110 a, 110 b, 110 c, 110 d, 110 e, 110 fand 110 g of pipe, which are also mounted on skids. FIG. 3 shows anexpanded view of a portion of the production system shown in FIGS. 1 and2, wherein high pressure separators 10, 20, 30, 40, low pressureseparator 50, fuel gas scrubber 60 and pipe rack sections 110 a, 110 b,110 c, 110 d, and 110 e are shown. As also shown in FIG. 3, variousinstrumentation devices, including flow, level, pressure control andcontrol valves are shown for the production equipment systems. FIG. 4 isa subset of the production system depicted in FIGS. 1-3, wherein highpressure separator 40, fuel gas scrubber 60, and pipe rack sections 110d, 110 e are shown. As shown in FIG. 4, although pipe rack section 110 eis shown, low pressure separator 50 is not shown and only the pipingconnections are shown.

As discussed above, over time a well's oil production can decrease byfifty percent (50%), which results in equipment, such as separators thatwere originally installed with the inception of the well, now beingoversized. However, replacing the equipment with smaller, less expensivein both initial and operating costs would require the production well tobe shutdown and the system purged in order to perform the requisitewelding and running of the various electrical, piping and pneumaticconnections. In some cases the production capabilities of a well mayhave been underestimated and therefore results in the installedequipment being undersized. Embodiments of the present invention resolvethese issues and allow for the contraction or expansion of oilproduction systems using skid mounted components, without the need forwelding onsite.

FIGS. 5, 6A and 6B depict an embodiment of the invention for a three (3)well (well 1, well 2, and well 3) production system having well manifold120 and high pressure separators 140, 150 and 160. No low pressureseparator is depicted in FIG. 5. FIGS. 5, 6A and 6B also depict skid130, which includes fuel gas scrubber 135, and pipe rack 200, which piperack 200 is made of multiple pipe rack skid sections. FIG. 5 alsoincludes tank battery 170, vapor recovery tower 175, flare knock-outdrum 180 and flare stack 190. FIGS. 6A and 6B also show heat exchanger205 within pipe rack 200.

In an embodiment of the invention depicted in FIGS. 5-7, and as can bemore readily seen in FIG. 6B, high pressure separator 160 is larger thanhigh pressure separator 150, and high pressure separator 150 is largerthan high pressure separator 140. As shown in FIG. 6A, only well 1 andwell 2 have separators 140 and 160, wherein separator 140 is connectedto well 1 and separator 160 is shown disconnected from well 2.Additionally, in accordance with an embodiment of the invention, the oilproduction modular system includes blinded piping and skid systems thatcan be used as additional wells are developed. For example, manifold 120includes piping for well 1 and well 2, as well as additional piping 121that can be used to commission a new well, e.g., well 3. Similarly, piperack 200 includes piping skid section 206 that can be used as additionalwells are developed. Referring to FIG. 6A, during normal operation ofthis two well production system, well 1 provides production feed toseparator 140, and well 2 provides production feed to larger separator160.

In a further aspect of an embodiment, overtime, the production of well 2begins to decrease, such that the large separator 160, that likely hadbeen used since well 2's commissioning is now oversized. The operatorcan remove separator 160 from being associated with well 2, and asmaller separator 150 can replace larger separator 160 as shown in FIG.6B. As also shown in FIG. 6B, rather than purchase a new separator fornew well 3, well 3 is configured to provide production feed to largerseparator 160, which had previously been used for well 2. In normaloperation, well 1 provides production feed to separator 140, well 2provides production feed to separator 150, and well 3 providesproduction feed to separator 160 as shown in FIGS. 5, 6B and 7.

As shown in FIGS. 5, 6A and 7, because the production capacity in well 2had been diminished, embodiments of the present invention allowed thelarger, more expensive separator 160 to be used with new well 3, and asmaller less expensive separator 150 to be used with existing well 2,without the need for welding. The replacement is quick and does notrequire that all of the production wells to be stopped and the systemspurged due to the need for welding piping components.

An example of the removal and replacement of modular skid systems whilethe oil production processing system is in operation is now described.Referring to FIGS. 5, 6A, 6B and 12, open sand leg of separator 160 byopening block valves 305 and adjustable choke valve 306 causing sand todrain into sand leg discharge pipe 307. Block in well 2 at the wellmanifold 120. Drain separator 160 of oil and water fluids. In separator160, close gas outlet, oil outlet, and water outlet by for example usingblock valves in pipe rack 200. Depressurize any residual gas pressure inseparator 160. Remove flange nuts at separator 160 gas inlet. Removeflange nuts from separator 160 process gas outlet pipe flange at thepipe rack 200 junction. Remove flange nuts from separator 160 processoil outlet pipe flange at the pipe rack 200 junction. Remove flange nutsfrom separator 160 process water outlet pipe flange at the pipe rack 200junction. Disconnect tubing connections 230 (see FIG. 10) of pneumaticmanifold at separator 160 pipe rack 200 junction. Disconnect electricalconnections 240 (see FIG. 10) at junction between separator skid 160 andpipe rack 200. Remove separator 160 from pipe rack 200 by pullingseparator 160 away from pipe rack 200 to disengage knife 220 and fork210. Using a crane or other suitable mechanism, lift separator 160 skidwith, e.g., lifting eyes, and reposition separator 160 out of the way.

To replace the larger separator 160 with smaller separator 150, afterlarger separator 160 has been removed, place smaller separator 150 inclose proximity to pipe rack 200 skid. Using the alignment guide platesof fork 210, pin 215, and knife 220, push separator 150 into position atpipe rack 200 skid until knife 220 and fork 210 alignment plates and pin215 engagement occurs. Connect tubing connections 230 (see FIG. 10) ofpneumatic manifold at separator 150 pipe rack 200 junction. Connectelectrical connections 240 (see FIG. 10) at junction between separatorskid 150 and pipe rack 200. Install ⅛″ gaskets between flange pairs forwell head inlet, and gas, oil, and water outlets. Install studs andnuts, torque to specification. Follow pressurization and start-upprocedure per facility. As shown, replacing oversized and largerseparator 160 with the smaller separator 150 did not require anywelding, that would require the entire production well site to be shutdown and the system purged in order to perform the requisite welding andrunning of the various electrical, piping and pneumatic connections.

In another embodiment of the present invention, additional parts are orthe entire production system is constructed on skid section systems asdisclosed herein, wherein component pieces of the system, including piperacks 110 a-110 g, 200, vapor recovery tower 175, flare knock-out drum180, flare stack 190, fuel gas scrubber 60, and a multi-well separatorare constructed and designed to be replaced in a modular form. Themodular construction and replacement of additional equipment inaccordance with an embodiment of an invention include, high-pressuretest separators, low-pressure test separators, line heaters, heatertreaters, gas dehydration units, gas powered units, combustors, slugcatchers, bulk separators, sand separators, methanol injection skids,pig launchers and receivers, safety systems, instrumentation andelectrical equipment skids, SCADA systems, flares, and other equipmentthat may be used at a well head production system.

Cold Weather Packaging Modular Production System

FIG. 16 illustrates a further aspect of the modular production systemembodiment, wherein a cold weather packaging modular production systemis provided. In these systems, the piping is heat traced and insulatedin a complete package prior to delivery, including the pipe rack pipingsections and equipment skid piping. The heat trace on the piping caninclude connectors or terminators for connecting the ends of the heattracing across the pipe rack and equipment skids during installation.The equipment, such as separator skids 510, 520 can also be outfittedfor cold weather operation, including insulated vessels and heated steelbox frames 515, 520 that cover the instrumentation and controls toshield equipment from cold winds to avoid freezing of condensed liquidsin the tubing control lines and control valves. Further, the separatorcan be a heated type that includes a fire-tube to promote gas-liquidseparation in cold environments.

Knife and Fork Alignment Pin

As more fully depicted in FIGS. 6A, and 6B through 11, the skid systemsinclude knife 220 and fork 210 pin connectors connected to the rigidbeam structures that are used to align and connect the skids. Forexample, the skid systems depicted in the figures can be mounted onsteel I-beams. Referring to FIGS. 8-10, and 14-15, the knife 220 andfork 210 pin connectors are alignment guide plates with a self-settingelevation pin 215 slot. Each fork 210 includes two guide plates that arewelded at one end to the beam web. The other end of the fork 210 guideplates include angled projection portions. The angled projections offork 210 help guide the skids into alignment as they are pushedtogether. A side sectional view of one guide plate of fork 210 is shownin FIG. 14A. As shown in FIG. 14A, the guide plate is welded at one endto beam web, and the other end includes an outwardly angled portion. Asshown in FIG. 14, the fork 210 includes pin 215 that can be a smalllength of round stock bar that can have a length slightly greater thanthe skid beam web thickness. The pin 215 is welded between the fork 210two guide plates to keep the free end of the fork 210 guide platesseparated. Pin 215 serves as the self-leveling pin as the fork 210engages the knife 220 while riding in the pin slot. As shown in FIG. 15,the knife 220 slot can be an elongated rounded cutout that is engagedwith the fork 210.

Additionally, other designs of the fork connector can include the guideplates being welded to a beam web without the intervening pin spacerthat is welded to both side plates. Here the two skid sections aresecured together by the open space between the guide plates engaging theweb of the opposing skid section beam. Additionally, an embodiment ofthe invention includes a single guide plate, such as that shown in FIG.14A. In this embodiment, as more fully shown in FIGS. 21A, 21B, and 21C,the guide projection 221 is a single plate that is welded to the web ofthe beam, and includes an outwardly angled end, so that the angled sideconnects with the web of the opposing beam and guides the skids intoalignment as they are pushed together. As the skid sections are pushedtogether, the guide projection 221 bumps the web of the opposing skidsection into proper alignment. As shown in FIGS. 21B and 21C, when theskids are pushed together using the alignment guide 221, it leavescompanion flange faces from opposing skids ready to bolt up with minimalfinal adjustment of pipe headers and ready for a gasket insert.

As shown in FIG. 11, an embodiment of the present invention is designedsuch that as the skids are pushed together and aligned using thealignment knives 220, forks 210 and pins 215, the interconnectingflanges 250 are pushed up leaving a ⅛ inch gap in order to slide in thenecessary gasket. In a further embodiment of the present invention asshown in FIG. 11, the system the skid systems include conductorscarrying electrical signals for power, signal, measurement or control ina quick connect type system that are connectable to conductors in otherskid systems of the production system by the connection of conductorcarrying conduits or emt tubing 240 within the systems, or terminatingconnectors on the skid systems, which removes the need to run wire andconduit during the installation at the production well site. In afurther aspect, cable trays are provided on the system to install“pre-run” electrical cable that is combined with skid-edge mountedjunction boxes populated with terminal blocks.

In a further embodiment, as shown in FIG. 11, the skid systems alsoinclude tubing 230 jumpers for pneumatic connections between the skidsystems, which removes the need to run tubing during the installation ofa skid system at the production well site. As shown in FIG. 7, skid 150a represents a portion of the skid that high pressure separator 150 asseen in FIG. 6A is mounted on. Referring back to FIG. 7, skid 140 asimilarly shows a portion of the skid base that high pressure separator140 is mounted on, and skid portion 130 a represents a portion of skid130 wherein fuel gas scrubber 135 is mounted. As is further illustratedwell manifold 120 is shown pulled back before hook up with the matingflanges on pipe rack 200 and hook up of the knife 220 and fork 210, suchthat when the knife 220 and fork 210 (also depicted in FIG. 9) areconnected as similarly depicted between skid portion 130 the flanges onwell manifold 120 are mated to the flanges on pipe rack 200 for boltingthe flanges one to the other. Still a further aspect of an embodiment ofthe present invention can include the use of testing components such astesting separators for use with single or multiple wells. FIG. 8 is anenlarged view of FIGS. 5-7 showing skid portion 130 and the piping andalignment pin connections.

Integrated Separator System

FIGS. 12A, 12B, and 13 illustrate an aspect of an embodiment, depictingan integrated sand separator system 300 in one or more of the highpressure separators 10, 20, 30, 40, 140, 150 and 160. In thisembodiment, the high pressure separator 10 is connected to the wellheadand includes an internal sand separator system 300 disposed within thehigh pressure separator 10. The sand separator system 300 filters outthe majority of the sand from the well head fluid stream. The sandseparator system 300 includes a sand weir plate 301 that is locatedbefore an oil weir 302. The sand weir plate 301 is lower that the oilweir 302 in order to collect the sand and keep it from reaching thewater out nozzle 303. During operation, sand enters the high pressureseparator 10 with the incoming well head fluid inlet 315 and impingesupon an inlet diverter 310 mounted inside the separator vessel 10. Whenthe sand granules impact the inlet diverter 310, a change in momentum ofthe sand granules is created; causing the sand granules to separate fromthe fluid and fall to the bottom of the high pressure separator 10 wherethey are collected at the base of the sand weir plate 301.

Sand system 300 can further include a drain system that includes sandout nozzle 304, double block valves 305, adjustable choke valve 306, andsand leg discharge pipe 307. As shown in FIGS. 12 and 13, the sand legdischarge pipe 307 is routed around the water drain piping 308. The sandleg discharge pipe 307 ties back into the water out header downstream ofinstruments (for example a vortex flow meter that can be inserted inspool 311) and liquid control valve 312 to avoid the sand's interferencewith or damaging the instrumentation. The sand system 300 can alsoinclude a self-cleaning feature, wherein after the separated sandgranules are collected at the base of the sand weir plate 301, the sandis drained from the high pressure separator 10 using a sand choke valve306, eliminating the need to shut down the system to vacuum remove thesand.

In yet another aspect of an embodiment of the present invention, a levelmeasuring device 313, such as an ultrasonic/sonar level device, a radarlevel device, an ultrasonic level device, or a capacitance level devicemeasures the level of collected sand and communicates this level to thecontrol or monitoring system (not shown). A further aspect of anembodiment can include choke valve 306 having an actuator or a separateactuator controlled control valve, wherein the control system actuateschoke valve 306 or control valve to drain the sand from the highpressure separator 10. The control system can also be programmed to senda signal to open the actuated choke valve 306 or control valve based onwhen the sand level, as measured by level device 313, reaches a desiredsetpoint.

Stacking Posts

FIGS. 17-19 illustrate a further aspect of another embodiment, depictinga stacking system for shipment of multiple pipe racks and otherequipment skids (see FIG. 19) that results in reducing the number oftrucks needed to transport production system components. As shown inFIGS. 17-19, four pipe racks 405, 410, 415 and 420 are stacked fortransport and delivery. Stacking posts 401 have top 402 and bottom 403plates with bolt holes. The stacking posts 401 are bolted to the piperack steel beams 406, 411, 416, and 421 at multiple places along thepipe rack in order to distribute the load. As can be seen in FIG. 19,the stacking posts 41 can be sized as needed to accommodate the multiplepipe racks. By using the stacking system embodiment, multiple pipe rackscan be shipped on one truck load, as opposed to four, reducing the costof shipping and speeding up the time of delivery and setup of themodular production system.

Data Analytics and Neural Networks

In a further aspect of an embodiment, the system includes a controlsystem, such as a DCS, PLC, SCADA, or wireless control system (e.g.,wireless instrumentation and control devices that communicate over awireless network), or a combination of these types of control systemsthat are operatively in communication with the modular productionsystem's instrumentation, actuators and valves. The control system canbe used to monitor and control the operation of the production system.Additionally, the system can be controlled and monitored remotely, andproduction system data for one or a multitude of production systems iscollected, analyzed, and used for benchmarking purposes, as well asoptimization and predicting operation of production systems, includingseparators, to generate and predict production systems operationalsetpoints, maintenance needs, measurements, and values, includingservice to the equipment, such as the need to drain sand from theintegrated sand separator. Additionally, the need to replace anoversized, or in some cases undersized separator, can also be determinedusing these systems. For example, and as shown in FIG. 20 and asdiscussed further below, there is data collection via a computercommunication network of production system operating parameters anddetermined setpoint data for a production system, including theseparator systems, wherein using data analytics, artificialintelligence, machine learning and/or neural network methodologies to:predict the subject, a related, or an unrelated production system'sperformance and/or operational setpoints; generate benchmarking metricsfor production systems' operation and maintenance; and/or generatesetpoints and anticipated measurement and production system operationalvalues.

FIG. 20 shows an example of a deep neural network (NN) architecture 600including a matrix of connected neuron processors. The matrix of neuralprocessors is configured as a computation unit that operates as atwo-dimensional systolic array. The two-dimensional systolic arrayincludes multiple cells that are configured to identify probabilitiesfor three categories of content. By way of example, the input neurons x1through x3 are activated through input data and operate as sensors thatperceive the input, and are for example in an embodiment of theinvention, well production data, such as measurement data that isreceived from well and separator instrumentation, and can include inletwell fluid flow rate, outlet fluid, including gas flow, oil flow, waterflow, system pressures, sand level, water level, and oil level, physicaland chemical characteristics of the crude, operating pressure, operatingtemperature, and rate of throughput, including rate of increase or rateof change of these parameters. Production system can includeinstrumentation that can measure these parameters, and data from theseparameters can be collected using a wireless network in communicationwith the instruments, and control or monitoring systems.

The middle layers, sometimes referred to as the hidden layers, whichinclude neural processor layers h11 through h14 and h21 through h24, areactivated through weighted connections and receive activation data fromprevious neural processors. For the sake of simplicity, two middlelayers are shown although these layers can be multiples of what is shownand the number of layers depends upon the input and how “deep” of anaccumulative learning process is required to obtain a reliable result.Some of the neural processors in the middle layers will influence theoutput by triggering events based upon one or more other eventsoccurring in the middle layer or directly from input data. Dependingupon the accuracy and comprehensiveness of the input data, the problemto be solved and how the neural processors are connected, obtaining anoutput z1 and z2, in order to, for example, predict timing of the needto drain the sand from the high pressure separator. As shown in FIG. 20the deep neural network 600 is configured to analyze each of the vectorsto generate probabilities to determine a final confidence score for theoutput z1 and z2 that reliable within a degree certain.

Although the apparatuses and methods described herein have beendescribed in detail, it should be understood that various changes,substitutions, and alterations can be made without departing from thespirit and scope of the invention as defined by the following claims.Those skilled in the art may be able to study the exemplar embodimentsand identify other ways to practice the invention that are not exactlyas described herein. It is the intent of the inventor that variationsand equivalents of the invention are within the scope of the claimswhile the description, abstract and drawings are not to be used to limitthe scope of the invention. The invention is specifically intended to beas broad as the claims below and their equivalents.

What is claimed:
 1. A skid mounted integrated petroleum separationsystem comprising: a. a horizontally oriented separator with a ventralside connected to a dorsal side of a skid, the horizontally orientedseparator with a separator body further comprising: i. a proximallyoriented wellhead fluid inlet extending from outside the separator bodyto inside the separator body; ii. an inlet diverter within the separatorbody positioned distally from the wellhead fluid inlet; iii. a sand weirplate within the separator body positioned distally to the inletdiverter; iv. an oil weir within the separator body positioned distallyto the sand weir; v. a sand drain proximal to the sand weir; vi. a waterdrain proximal to the oil weir and distal to the sand weir; vii. an oildrain distal to the oil weir; and viii. a sand level measuring deviceproximal to the sand weir; and b. a skid with a dorsal side mounted tothe ventral side of the horizontally oriented separator.
 2. The skidmounted integrated petroleum separation system of claim 1, furthercomprising a sand leg discharge pipe connected to the sand drain.
 3. Theskid mounted integrated petroleum separation system of claim 1, furthercomprising water draining piping connected to the water drain.
 4. Theskid mounted integrated petroleum separation system of claim 2, furthercomprising a vortex flow meter connected to the water draining piping.5. The skid mounted integrated petroleum separation system of claim 2,further comprising a liquid control valve connected to the waterdraining piping.
 6. The skid mounted petroleum separation system ofclaim 1, further comprising a sand choke valve.
 7. The skid mountedpetroleum separation device of claim 1, wherein the sand level measuringdevice is a sonic measuring device, a radar measuring device, acapacitance measuring device, or a combination thereof.
 8. The skidmounted petroleum separation device of claim 7, wherein the sand levelmeasuring device sends a signal to remove sand from the separator. 9.The skid mounted petroleum separation device of claim 8, furthercomprising a control system, and wherein the signal sent by the sandlevel measuring device is sent to the control system.
 10. The skidmounted petroleum separation device of claim 9, further comprising oneor more actuated valves, and wherein the control system controlsactuation of the one or more valves upon receiving a signal from thesand level measuring device.
 11. The skid mounted petroleum separationdevice of claim 1, wherein the skid comprises a set of spaced apartbeams and: a. an alignment beam fork member coupled to at least one ofthe beams comprising a first guide plate and a second guide plate and afirst alignment pin disposed between the first and second guide plates;and b. an alignment beam receiving member coupled to at least one of thebeams.
 12. A method of operating a skid mounted petroleum separationdevice comprising: providing a separator mounted on a skid module, theseparator comprising: a proximally oriented wellhead fluid inletextending from outside the separator body to inside the separator body;an inlet diverter within the separator body positioned distally from thewellhead fluid inlet; a sand weir plate within the separator bodypositioned distally to the inlet diverter; an oil weir within theseparator body positioned distally to the sand weir; a sand drainproximal to the sand weir; a water drain proximal to the oil weir anddistal to the sand weir; an oil drain distal to the oil weir; and a sandlevel measuring device proximal to the sand weir; an actuated valveconnected operatively connected to the sand drain; a control unit;connecting a wellhead to the wellhead fluid inlet; flowing a liquidpetroleum product from the wellhead into the separator through thewellhead fluid inlet of the separator; trapping sand from the liquidpetroleum product with the sand weir plate; measuring a level of sandtrapped by the sand weir plate with the sand level measuring device;sending a signal to the at least one actuated valve through the controlunit to actuate the valve open and drain sand from the separator uponreaching a set upper level of sand; and sending a signal to the at leastone actuated valve through the control unit to actuate the valve closedand stop draining sand from the separator upon reaching a set lowerlevel of sand.
 13. The method of claim 12, wherein the level measuringdevice is an ultrasonic level device, a radar level device, or acapacitance level device and the method further comprises sending asignal from the level measuring device to the control system.
 14. Themethod of claim 13, wherein the signal is a wireless signal.
 15. Themethod of claim 13, wherein the signal is a wired signal.
 16. The methodof claim 13, further comprising programming the control unit to actuatethe sand valve on at least one predetermined setpoint and wherein thelevel measuring device sends a signal to the control systemcorresponding to the at least one setpoint.
 17. The method of claim 12,wherein the first skid module further comprises a first piping manifoldfor fluid flow having a first piping manifold connection assembly havingat least one first piping manifold connection assembly having at leastone first piping manifold mating flange, and a first set of spaced apartbeams on which the first piping manifold is mounted; and furthercomprising a second skid module comprising a second piping manifold forfluid flow having a second piping manifold connection assembly having atleast one second piping manifold mating flange, and a second set ofspaced apart beams on which the second piping manifold is mounted; andwherein the method further comprises: providing a first alignment beamfork member coupled to at least one of the beams of the first skidmodule or at least one of the beams of the second skid module, the firstalignment beam fork member comprising a first guide plate and a secondguide plate, and a first alignment pin disposed between the first andsecond guide plates; providing a first alignment beam receiving membercoupled to at least one of the beams of the first skid module or atleast one of the beams of the second skid module, wherein the firstalignment beam fork member and the first alignment beam receiving membercomprise a module connection assembly; and aligning the first skidmodule with the second skid module; and mating the alignment beam forkmember of one module of the first or second module to the alignment beamreceiving member of another module of the first or second module;concurrently mating the flange of the first piping manifold to theflange of the second piping manifold.
 18. The method of claim 17,further comprising flowing oil drained from the separator through thefirst piping manifold into the second piping manifold.
 19. The method ofclaim 17, further comprising an electric conduit on each module capableof transmitting electronic signals from one module to another, andwherein the method further comprises sending signals from the levelmeasuring device through the electric conduit to the control system. 20.The method of claim 19, further comprising a pneumatic conduit on eachmodule capable of transmitting pneumatic signals from one module toanother, and wherein the method further comprises sending gas pressurethrough the pneumatic conduit from the control system to actuate the atleast one actuated valve to an open or closed position.